mem05010c apply fabrication, forming and shaping ...mem05010c. apply fabrication, forming and...

MEM05 Metal and EngineeringTraining Package

Learner guideVersion 1

Training and Education SupportIndustry Skills Unit

Meadowbank

Product Code: 5776

MEM05010CApply fabrication, forming and shaping

techniques (Heavy Edition)

SAMPLE

MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)

© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013

CONTENTS

Introduction ..........................................................................................................5

Topic1 SquareandRectangularDucting................................................................9 1.1 TruncatedRectagularDucting ..........................................................................22

Topic2 CylindricalFabrication.............................................................................29 2.1 Theory&CalculationsrelatingtoRollingaCylinder ........................................29 2.2 TruncatedCylinderwithFlanges ......................................................................53 2.3 Therory&CalculationsRelatingtoLobster-backBends ..................................59 2.4 Theory&CalcuationsRelatingtoCylindricalSquareBranches& WrapAroundTemplates ..................................................................................75 2.5 InclinedBranchOn-Centre ...............................................................................85 2.6 InclinedRectangularBranchonaCylinder(On-Centre) ..................................93

Topic3 ConcialFabrications...............................................................................101 3.1 FormingMainBarrel ......................................................................................118 3.2 FrustumofRightConewithFlange ................................................................122 3.3 TruncatedRightCone .....................................................................................127 3.4 FormingTruncatedRightCones .....................................................................138 3.5 Multi-strakeCone ..........................................................................................151

Topic4 TransitionalFabrications.......................................................................165 4.1 Theory&Calculations ....................................................................................167 4.2 RectangulartoSquareHopperTransition ......................................................178 4.3 Square/RectangulartoRoundTransition .......................................................183 4.4 SquaretoRoundTransition............................................................................189 4.5 Off-CentreSquaretoRoundTransition ..........................................................195 4.6 CylinderJoiningPiece ....................................................................................203 4.7 SubAssembleofJob4.5&4.6 .......................................................................207 4.8 SquaretoRoundTransition(RoundCorners) ................................................208 4.9 FinalAssembly-TransitionPieces .................................................................220

Project Manager:Stephen DaviesEducation Programs ManagerTAFE NSW

EnquiriesEnquiries about this and other publications can be made to:

Training and Education Support Industry Skills Unit, MeadowbankMeadowbank TAFELevel 3, Building J,See Street,MEADOWBANK NSW 2114

Tel: 02-9942 3200 Fax: 02-9942 3257

© TAFE NSW (Training and Education Support, Industry Skills Unit Meadowbank) 2013

Copyright of this material is reserved to TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank. Reproduction or transmittal in whole or in part, other than for the purposes of private study or research, and subject to the provisions of the Copyright Act, is prohibited without the written authority of TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank.

ISBN: 978 1 74236 484 1

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Topic 1 - Square and Rectangular DuctingTheory and calculations square/rectangular fabrications

Student Organiser

Topic Activity

1 Square/Rectangular Ducting

1.1 Truncated Rectangular Duct• Theory/Calculations• Job 1.1 - Truncated Rectangular Duct • Review questions

Job Planning for Square/Rectangular Fabrications

Careful job planning is required for all types of fabrication work. Planning enables work to be carried out in an organised way, setting out each step (the sequence) in a sensible, logical order, will assist in making the finishedproductmeettherequiredstandardofquality.

There are three (3) stages to the job planning process.

NOTE: All employees in the workplace are responsible for quality control and safety.

To ensure the finished product is made to specifications, the fabricator will need to progressively check each step of the fabrication process

Stage 2Fabrication

Careful pre-planningfrom the start gives you more control over the entire fabrication process

Stage 1Pre-planning

Stage 3Finished product

Effective quality control is a key to success for any business. Without quality control the results for the company could be costly

• Interpret drawings• Task sequence• Organising equipment• Make working drawings• Develop patterns and/or templates

• Selection of material• Mark out• Cutting• Forming• Joining• Finishing• Installing• Final quality check

• Loss of repeat work• High labour cost to do recall / wattanty work• Material losses• No recommendation for other work• Company closure and unemployment

Ducting with flanges

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Drawing Interpretation of Square/Rectangular Fabrication

Correctinterpretationofworkshopdrawingsisvitalifthefinishedfabricationistomeetitsspecifiedsize,shape and tolerance.

The material used for making ducting varies depending on its application. The most common material used is low carbon steel as it has good workability, structural strength and a relatively smooth surface which helps airflow.Ductingcanalsobemadefromstainlesssteel,aluminium,copperandplasticmaterials.

Development methodParallel line development is the method used to develop square/rectangular shapes, using a series of parallel lines.Thepatternisclearlyseenwhentheshapeisfoldedoutflat.

Marking outInvolves three main steps:

1. Calculating required dimensions2. Laying out and developing the pattern/template3. Following production instructions

800 mm

200 mm 200 mm 200 mm 200 mm

H=

600

mm

115

mm231 mm

h=

485

mm

DIAGONALS=1000mm

60°

Pattern calculationsPattern length

Length = Sides x 4 = 200 x 4 = 800mm

Diagonal length check of pattern

=√ Pattern length² + Pattern height ²

=√800² + 600²

=√ 640000 + 360000

=√ 1000000

= 1000 mm

60° Height check Tan Ø = opp Tan30° = X adj 200therefore X = 200 x tan 30°

= 200 x 0.577 = 115.4

= 115 mm

True length check of truncated slope

² =√115 ² +200

=√13225 + 40000

=√53225

= 231mm

Pattern little height (h)

= Pattern height - 60° height

= 600 - 115

= 485 mm

800 mm

600 m

m

Diagonal length=1000 mm

60°

200 mm

115 m

m

Truncated length= 231 mm

60°

200 mm

X =1

15 m

m

30

Truncation Angle

°

Example

Example

Example

Pattern

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Bend calculations/allowances

When calculating the stretchout length of a pattern for square/rectangular ducting you must allow for the thickness of material.

Stretchout lengths for material 3mm thick (or under) are calculated using the inside measurements of the ducting, because the amount of material loss in the bend to 90° is small.

600 mm

200 mm O/S

200 m

m O

/S

radius

3 mm sheet

NOTEO/S = outside dimensiont = material thickness

Calculation:I/S Length = (O/S – 2 x t) + (O/S – 2 x t)

= (200 - 2 x 3) + (200 – 2 x 3)

= (200 – 6 ) + (200 – 6) = 194 + 194 = 388 mm

Half stretch pattern

2 required @ 3 mm by 388 x 600 mm sheet

194 mm I/S 194 mm I/S

388 mm

600

mm

Ben

d up

to 9

0º

When calculating the stretchout length of material greater than 3mm in thickness you must take into account the amount of material loss in the bend to 90°.

IR 9 mm

600 mm

194 mm I/S

194 m

m I/

S

6 mm plate

NOTEI/S = inside dimension IR = inside radiusID = inside diameter MD = mean diameterMC = mean circumference

Calculating distance around 90° bendID = IR x 2 MD = ID + t = 9 x 2 = 18 + 6ID = 18 MD = 24

¼ MC = MD x 3.1416 (�) 4 = 24 x 3.1416 4 = 75.3984 4 = 18.8496 Say = 19 mm

Half stretch pattern

2 required @ 407 x 600 x 6 mm plate

600 m

m

19 mm allowance

194 mm 194 mm

Bend

up to

90°

407 mm

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Practical method to calculate the bend allowance

Anoutsideflangewidthof160mmisrequired.Tofabricateanaccuratebenditisrecommendedthatyouadopt the following procedure using a sample piece of identical material which is used for the job.

STEP (1)Measure a distance from a pre-marked datum lines for the bend, as shown below:

150 mm 150 mm

50 50

10 mm plate

STEP (2)Now bend this to the required angle (i.e. 90°)

NOTE: The 58mm dimension is used as an example

STEP (3)The sketch shows there is a 2mm reduction on each end. In turn you will have to increase your inside measurementto152mmtomakeafinishedoutsideflangewidthof160mm.

158 mm

58

158

mm

58 50

50

10 mm

50 mmdistance each side ofthe centreline

158 m

m

158 mm

Production instructions

Production instructions are the markings on fabricated jobs and components. Their purpose is to identify the component and clearly show what is to be done on (or with) the component. These instructions often determine the way a job is done and how the sequence of operations is carried out. The sketch below shows a typical example:

Pres

s ove

r to

90°

Pres

s ove

r to

90°

Gui

llotin

e cu

t

Guillotine cut

BAP

BAP

Guillotine cut

Guillotine cut

before pressing

Oxy cut beforepressing

J/N 373/4O/N 8/3/07Item A

Plate edge

Materials are cut by mechanical or thermal processes, the following are typical examples.

Mechanical cutting

1. Guillotines2. Bench shears3. Nibblers 4. Shears

When using mechanical cutting equipment you must comply with all safe operating procedures and OHS requirements.

Thermal cutting

1. Oxy-fuel gas cutting is used for any shape cut on low carbon steel.2. Plasma cutting is often used for cutting and shaping low carbon, stainless steel, aluminium and other

non ferrous alloys.

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The choice of cutting procedures depends on:• Material thickness• Type of material• Machine cutting capacity

On some jobs, there are sections which stay uncut until forming has been completed.

This is shown by using the following initials:

BAR (Burn or cut after rolling) BAP (Burn or cut after pressing)

Forming lines and bends

These lines show where bends and radii etc, will be. They also show the forming diameters/radii and/or angles to be pressed. This information should be shown on the side on which the component is to be formed. For example, bend/roll up, down or over and forming sequence.

Pressing

Machines used for this purpose include:

• Gap press • H-frame press • Brake press• Folder

Bending techniques

The bending of metal parts in a brake press can be done by air bending or bottoming.

Air bending means the material is not forced completely into the bottom die. There is some space between the underside of the material and the bottom of the vee die.

Bottoming means the material is formed between the upper and lower dies, which close completely with only the material separating them.

General rule:-

The Vee die (Vee block) opening should be at least 8 times the material thickness with the die angle between 80° to 88°.

Vee block

8 x materialthickness

Veeblade

60º - 88º

Radius equal to½ material thickness

80º - 88º

Example calculating Vee die opening:

Material: 5 mm plate

Vee width = 8 x 5

= 40 mm Vee block

Minimum bend radius is calculated by:

Inside radius = 1.5 x thickness of plate

Example: 5 mm plate

Bend radius = 1.5 x thickness

= 1.5 x 5

= 7.5 mm minimum bend radius

t

R = 1.5t

Note: Vee-Blade angle must always be less than Vee-Block angle.

Brake press SAMPLE



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Data sheet from manufacturers give information regarding: - material thickness, minimum bend radius, die opening and required force (tonnes/lineal metre).

The chart below is from an 80 tonne hydraulic press brake, for material up to 10mm thickness.

MIN. LEG LENGTH B (mm) 5 6 8 9 12 15 18 22 26 29 33

INSIDE RADIUS OF BEND (mm) 0.8 1.0 1.25 1.5 2.0 2.5 3.12 3.75 4.4 5.0 5.6

FEMALE DIE OPENING (mm)

MAT

'L T

HIC

KNES

S (m

m)

6 8 10 12 16 20 25 30 35 40 45 1 11.4 8.55 6.84 5.70 4.28

1.2 16.4 12.3 9.85 8.21 6.16 4.93 1.6 21.9 17.5 14.6 11.0 8.76 7.01 2 27.4 22.8 17.1 13.7 11.0 9.12 7.82

2.5 35.5 26.7 21.4 17.1 14.3 12.2 10.7 3 38.5 30.8 24.7 20.5 17.6 15.4 13.7 4 54.7 43.8 36.5 31.3 27.4 24.3 5 85.5 68.4 57.0 48.9 47.8 38.0 6 98.5 82.1 70.4 61.6 54.7 8 146.0 125.0 110.0 97.3 10 171.0 152.0

TONNES FORCE REQUIRED PER LINEAR METRE TO BEND LC STEEL THIS CHART BASED ON STEEL 440 MPa U. T.S.

Data Chart

The sketch below shows the minimum return bend allowance.

Inside bend radius

B

Die opening

Die BlocksAre available in many different shapes and forms.

Vee BlocksTypes of Vee blocks used to form bends include:

• Knife and Vee• Acute angle knife and Vee• Radius knife and Vee/former

Knife & Vee

Acute angle Knife & Vee

Radius knife & Vee

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Checking pressed shapes

Methods include:• Internal template• External templates• Check over layout

Internal template

External template

Check over layout

Assembly procedures for square/rectangular ducting

When assembling square or rectangular duct work ensure the fabrication is square, free of twist and joints are in alignment, prior to tack welding.

Assembly procedures include:

• Lineuponeedgecornertocorner,usingclamps,magneticlinksorjigsandfixtures• Line up the seam using light tack welds as required• Align the other seam diagonally opposite and tack weld• Checkforsize,squarenessandtwist

Regular checks will minimise errors, you should be especially careful when, aligning longitudinal corners joints such as:

Corner to corner Single bevel Corner lap

Aligning ends of component parts

• Square ends• Plates aligned and parallel

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Progressive checking

Regular checking is essential to prevent errors, if a minor error occurs, spread it around the job rather than confiningittooneplace.

152

150

correct

152

150

6mm plate corner to corner, the 152mm wide plate laps each side by 1mm (not to scale).

149

150

correct

149

150

6mm plate corner to corner, the149 mm wide plate is placed so 0.5mm gap is left each side

incorrect

incorrect

1 mm overlap

0.5 mmgap

(not to scale).

Progressive checking should include:

• Alignment of joints• Squaring of side plates• Checking for twist• Checking ends for squareness

Square offthe sideplates with a square.

Checking for twist using a square and a flat surface.SAMPLE



Page 17 of 224

Measure down bothsides of the straightedge, ensuring distances are equal.

This is an alternative method for checking for twist, using a straight edge.

Checking for square by measuring across the diagonals, to see if they are the same.

Checking ends for squareness using an Engineers square

Assembly aids for square/rectangular ducting

Tools and accessories can help you assemble a job more accurately. They include:

• G-clamps• Magnets• Fixed dogs and wedges• Temporary or permanent bracingSAMPLE



Page 18 of 224

G - Clamps

Magnets

Fixed dogs and wedges

To moveTack top only

tack

Tack weld

Tack weld

Pivotpoint

WedgesTo pull a stiffener into position

Temporary or permanent bracing

Cleat

Brace

90°

Packing

Gusset

Packing

Sub-assemblies

Large jobs are often fabricated as part of a sub-assembly. This is because sub-assemblies are easier to handle, reduce overall distortion, give greater accuracy and easier to transport. Extra planning will be needed for larger jobs. In relation to sub-assembles you need to check that:

• Workshop cranes can lift assembly or sub-assemblies• Thereissufficientclearanceforliftingandturningthesub-assembly

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Fabricating a Flange for Square and Rectangular Ducting

Flangesforsquareandrectangularductingaremadefromplate,flatbarorangle.Typesofflangesinclude:

1 piece flange from plate

4 piece flange fromflat bar or anglemitred cornersand welded

4 piece flange from flat bar or angle butt welded corners

Production procedures include:

• Marking out• Cutting• Drilling/punching• Assembly(for4pieceflange)• Tack welding• Checking

Marking out

Squareandrectangularflangesaremarkedoutandfabricatedusingeitheroneorfourpieces.

Step 1

Markoutahorizontalcentreline, about 100mm longer than required for the actual lengthoftheflange.

Step 2

From an approximate centre point,markoutthe½flangelength,then use these points to bisect top and bottom to locate the vertical centre line as shown.

Step 3

Measureoutthe½flangewidth using the vertical centreline, then use these pointsto locate the four corner points.

Step 4

Mark out the out side shape oftheflange.

Step 5

From the four cornersscribe arcs equal to theflangewidth.

Step 6

Mark out the insideflangeshape.

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Step 7

Markoutintheverticalandhorizontalcentre lines to locate hole centres.

Step 8

Tackweldflangeandlocateholesin the required places.

Cutting

• Onepieceflangesaremanuallyflamecut• Profilecuttingmachinesareusedtocutlargenumbers• A guillotine can be used to cut outside edges if the material thickness is within the machine’s capacity• Fourpieceflangescanbecutwithaguillotine,cropperormanuallyflamecut.

Drilling

Themethodyouusewilldependonthenumberofflangestobedrilled.Remembersmallnumbersofflangesare drilled separately or in pairs and large numbers using a template or jig. Before starting, decide if you should:

• Drill before or after assembly• Stack drill using a template or jig.

Template used forstack drilling

Assembly

This can be done on a layout or in a jig. Make sure your work is accurate and joints are correctly aligned.

Correct Incorrect

Fitting flanges to ducting

Alignmentofflangestoductingmustbewithintolerance.Checkthatyourworkhas:

• Correct overall length measurement• Flanges are square to duct• Flanges are correctly located.

Plate square

flangeduct

Equal dimensions

gooseneck

flangeduct

Welding flanges

Fillet weld

duct

preparationCorner weld

Forthebestdistortioncontrol,youshouldweldthecornerjointfirstandthenthefilletjoint.

NOTE:Corner weld should havemin 6 mm insertion or equal to the material thickness or whichever is less.

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Final fabrication checking

It is essential that you check your work for accuracy. Check your work for:

• Correct type of material• Correct thickness of material• Correctsize,bothinternalandexternal,oftheflangeandduct• Position of holes• Diameter of holes• Squarenessofflangeandduct• Alignmentofjointoftheflangeandduct• Quality of work.

Surface finish (painting or galvanising)

The job should include:

• Preparation of the surface• A decision on what should be painted and at what stage it should be painted• Protection of surfaces to avoid corrosion or mechanical damage prior to and after painting/

galvanising.

Delivery

Final delivery of the job (complete or sub-assembly) must be:

• In order of requirement• As soon after completion as possible• Without damage to the job or any of its surfaces.

Student Notes

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Assessment Criteria

1. To be dimensionally correct to within ±2mm2.Flangeisflat,i.e.,freefromtwistanddistortion3.Holeslocatedasspecifiedtowithin±2mm4. Flange is square to the centre line of the truncated square duct5.Flangespositionedasspecifiedtowithin±2mm6. Seam alignment to be within ±2mm.7. To be well constructed and neat in appearance

NOTE:-After completed job has been assessed, students are required to take the assemble job apart and their job will be used as a welding exercise at a later time.

Practical Sheet

Job 1.1: Truncated Rectangular Duct

Equipment required:

Marking out tools, hand tools, assembly aids, personal safety equipment, guillotines, press, forming blocks,drillingorpunchingmachine,flamecuttingandweldingequipment.

Job procedure

Student A1. Complete the associated exercises 2. Mark and cut items 1&23. Press items 1&24. Mark and cut items 5&75.Assembletheflangeitems5&76.Markanddrillholesintheflange7. Assemble items 1 to 28.AssembletheflangetoPartA.

Student B1. Complete the associated exercises 2. Mark and cut items 3&43. Press items 3&44. Mark and cut items 6&85.Assembletheflangeitems6&86.Markanddrillholesintheflange7. Assemble items 3 to 48.AssembletheflangetoPartB.

Final assembly

Student A & B1. Assemble Parts A to B.2. Present your completed job for assessment.

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3004

2

3

1

A A

60º

60º

7&8

5&6

Ø12 hls

Detail C

Flange detail Detail B

94

4794 322

94

20

20105105

250

142inside

dimension

Duct detail

Section A-A (without flange)

214Inside dimension

250

Detail A

FRONT VIEW

PART A

90º

PART B

Corner to corner jointDetail C

Pressed corner jointDetail B

NOTES:MaterialPart A- 350 x 500 x 3mm sheet- 50 x 500 x 5mm flat barPart B- 300 x 750 x 3mm sheet- 50 x 750 x 5mm flat bar

- Flange clearnace approximately 1mm all round- Use square butt joints for flanges- All measurements are in mm

Student A will fabricate Part AStudent B will fabricate Part BBoth students to assemble Parts A&B together

General tolerances± 2 mm

Flangeface

End of duct3 mm

Detail A

3 mm

DRAWNDATE

A Trainer SCALENTS01/07/09

A3 RECT / DUCT FAB IssueA

TITLE:- Rectangular duct

Job 1.1 Truncated Rectangular Duct

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Review Questions (Theory and Practical)

Job 1.1: Truncated rectangular duct

Question 1

a) Name the three (3) stages of job planning required to make a rectangular duct.

Stage 1:- _____________________________________________________________________

Stage 2:- _____________________________________________________________________

Stage 3:- _____________________________________________________________________

b) Give two (2) examples of each stage.

Stage 1:-

• _________________________________________________________________________

• _________________________________________________________________________

Stage 2:-

• _________________________________________________________________________

• _________________________________________________________________________

Stage 3:-

• _________________________________________________________________________

• _________________________________________________________________________

Question 2 (Calculations)

From the rectangular truncated duct drawing, calculate the following:-

a) Whatistheflangeallowancefor(PartsA&B)? _____________________________________________________________________________

b) Whatarethepatternheights(PartsA&B)?

PartA=Overallheight-flangeallowance=_____________=________

PartB=Overallheight-flangeallowance=_____________=________

c) The pattern length (PL) for Parts A & B = (length + width) x 2

ie. PL = 2 x (L+W)

PART A PART B

= _______________________ = ________________________

= _______________________ = ________________________

d) The diagonal length of pattern:-

Part A

Part B

²

Answer =

Diagonal A = √ Pattern length² + Pattern height

=√

=√

=√

Diagonal =

=√

=√

=√

Answer =

√ Pattern length² + Pattern height²

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e) The 60° height check (PARTS A & B)

Slant Height = Length x Tan (90º - truncation angle)

=

Answer =

f) Checking truncated slope length (PARTS A & B)

PART A

g) Small pattern height Small pattern height = Pattern height - Slope height h = H - SH = ____________________________________ = ____________________________________ Answer = ____________________________________

PART B

Small pattern height = ____________________________________ = ____________________________________ Answer = ____________________________________

Slope length (SL) = ² ²

=√

=√

=√

Answer =

√ Slant height + Pattern length

Question 3

Onthepatternsdrawnbelow,fillinthemissingdimensionsandcalculations:-

PART A

PL =

W = L = W = L =

H=

DIAGONALS=

°

SH =

SL =

h =

PART B

PL =

W = L = W = L =

H=

DIAGONALS=

°

SH =

SL =

h =

SAMPLE



Page 26 of 224

Question 4

Complete the parts list below for the truncated rectangular ducting job 1.1.

8

7

6

5

4

3

2

1

Item No. Description Length No. Req’d Mat’l

Question 5

On the pattern drawn below, insert the required production procedures for the rectangular truncated duct.

Part A & Part B

=

=

=

=

==

=

=

J/N 1.1PART A

Plate edge

Question 6

How many items are pressed to form Parts A & B.

__________________________________________________________________________________

Question 7

Whattypeofjointsareusedfortherectangulartruncatedduct?

• _____________________________________________________________________________

• _____________________________________________________________________________

Question 8

Describe in point form how to assemble the rectangular duct.

• _____________________________________________________________________________

• _____________________________________________________________________________

• _____________________________________________________________________________

• _____________________________________________________________________________

• _____________________________________________________________________________

SAMPLE



Page 27 of 224

Question 9

Drawtoascaleof1:2theflangedetailfortherectangulartruncatedductusingthecentrelinebelow.

Question 10

Whatdiameterholesarespecifiedfortheflange?

• _____________________________________________________________________________

Question 11

Whattolerancesaregiventofabricatetherectangulartruncatedduct?

• Ducts _______________________________________________________________________

• Flanges ______________________________________________________________________

Question 12

List the essential checking methods you should use on the completed rectangular truncated duct:

• _______________________________________________________________________________

• _______________________________________________________________________________

• _______________________________________________________________________________

• _______________________________________________________________________________

• _______________________________________________________________________________

• _______________________________________________________________________________

• _______________________________________________________________________________ SAMPLE



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Student Notes__________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________

Student Drawings/Sketches

SAMPLE

mem05010c apply fabrication, forming and shaping ...mem05010c. apply fabrication, forming and...

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